Professional Documents
Culture Documents
Eric Guether
Opnext, Inc.
Matthew Dooling
Opnext, Inc.
Introduction
This white paper is intended to explain how Opnext used Assemble-To-Order (ATO) Make functionality to
facilitate the outside processing of consigned components in direct response to customer sales orders. The
booking of customer sales orders in Order Mgmt. triggered the creation of discrete WIP jobs with an outside
processing step. Outside processing allowed the Assemble-To-Order process to transmit configuration
instructions to the 3rd party contract manufacturer in the form of an Outside Processing standard purchase
order and transact the consumption of a key component, held on consignment, when completing the final
assembly.
The scope of this white paper is to present E-Business Suite functionality via examples from a release
11.5.10.2 (CU2) instance. All functionality presented should be applicable to E-Business Suite Release 12.
The set-ups required for Assemble-To-Order or Outside Processing are outside the scope of this white
paper. Various E-Business Suite user guides and numerous OAUG presentations at the national level
already address such set-ups. Also out of scope are ATO Buy scenarios, referred to as Procure-To-Order
or back-to-back orders. Finally, Configure-To-Order using Oracle Configurator is not addressed.
Business Case
Opnext initiated a redesign of the business process to manufacture this product line in order to facilitate the
final configuration of FGs using common subassembly (SA) components. The existing CM would tweak its
processes so that one common subassembly could be used in any FG item within a product group. A
product group typically consisted of five or six unique FG item numbers. The final configuration lead time
under the redesigned business process would be two to three weeks. The common subassembly included
the long-lead items and represented 90% of the total manufacturing time and cost of the finished good.
Opnexts users envisioned a 2-PO model under the redesigned business process:
1. Issue a standard PO for the advance purchase of subassemblies.
2. Issue a standard PO for assembly services to configure the subassemblies into specific FG items.
The first POs for subassemblies would be placed twelve weeks in advance. The ordering of subassemblies
had nothing to do with ATO functionality. The creation of the subassembly POs would be driven by MRP
planning. The Opnext planner would upload a three-month forecast of subassemblies, based on product
group forecasts, into the master demand schedule. This eliminated the need to provide precise six-month
forecasts of specific products (unique item numbers). The CM would build the ordered subassemblies, bill
Opnext, and hold the SAs on consignment until consumed. The SAs would be added to Opnexts Oracle
EBS Inventory when built via receipts against the SA POs.
The second POs would be issued to the same CM for the assembly of a FG item once a firm customer sales
order for that item number was booked. These second POs represented an outside processing (OSP) PO
for services to assemble the finished good. The idea was that these second POs for OSP services should
be triggered, directly or indirectly, by the booking of a customer SO just like the concept behind
Assemble-To-Order functionality. In this case, the completion of FG assembly services needed to consume
the subassembly (previously ordered and built) from our Oracle Inventory.
System Solution
The system solution for this new business process was the combination of ATO Make functionality with
Outside Processing functionality. A key requirement was to automate as many steps in the process as
possible to minimize the need for manual user entry or interfaces with the CM.
Under the solution, the FG items in this product line would be set up as ATO Make items. Their OM
Assembly-to-Order flag would be checked on, their General Planning Make or Buy flag would be set to
Make, and their Build in WIP flag would be checked on.
The booking of a sales order for these ATO Make items would trigger the creation of a discrete WIP job.
The routing on the WIP job would have only one step an outside processing step. The OSP step would
create the second PO for the FG assembly services and cause the WIP job to consume the subassembly
upon completion. The completion of the WIP job would also create a reservation against the finished good
inventory for the SO line that had spawned the WIP job.
The process flow for this system solution is shown in Figure 2. A walkthrough of the steps in the flow is
presented in a later section of this white paper.
Figure 2 Process Flow of System Solution: ATO Make with Outside Processing
The relationship between sales orders, discrete WIP jobs, OSP requisitions, and OSP POs can be seen
through a Sales Backlog custom Discoverer worksheet in Figure 3. When the sales order line has a status
of PRODUCTION_OPEN, it indicates that the ATO Make process has spawned the creation of a WIP job. If
the SO line has a status of SUPPLY_ELIGIBLE, the line is eligible to create a WIP job but other factors
have prevented the jobs creation up to this point; for instance, a necessary concurrent request has not yet
run.
Figure 3 Discoverer Worksheet for Sales Order Backlog of ATO Make Items
The creation of discrete WIP jobs is controlled by the sales order line workflow (WF). When the workflow
spawns a discrete WIP job, it links the SO line to the WIP job. Figure 4 displays how Opnext added the
seeded ATO workflow process, Line Flow - ATO Item, to a line workflow assignment.
Figure 5 shows the seeded ATO WF process Create Supply Order - Line, Manual as a sub-process in
Opnexts custom SO line workflow.
Outside processing is seeded EBS functionality whereby components are typically shipped out (outbound
consignment) to a third-party supplier for OSP services. The functionality assumes that the assembled
items would be physically received and an OSP resource charge would be incurred. Outside processing
functionality creates Purchase Requisitions that generate OSP POs to the supplier of services and
ultimately consumes the consigned components that had been shipped out.
In Opnexts case under this system solution, the consigned components the common subassemblies
would not be shipped out, because the CM who built the SAs would just hold them on consignment.
The PO unit price on the OSP PO is the price for the assembly services, not the full value of the assembled
item to be received back. The PO unit price is usually set in EBS to the same value as the standard cost of
the OSP resource charge.
The standard cost of an ATO Make item under Opnexts system solution is the material cost of the
subassembly plus the OSP resource charge. For example, the rolled-up standard cost of ATO Make item
LASER123 would be calculated as follows based on the costs of its common subassembly, SA999, and
OSP resource charge:
Material Cost of Subassembly SA999
+ OSP Resource Charge
Rolled-up Std Cost of ATO Make Item LASER123
$900
+ $100
$1,000
Transaction Walkthrough
This section presents a walkthrough of the steps in the ATO Make with OSP process flow. Figure 6 below
is the same flow shown in Figure 2 with the addition of step numbers for reference.
Figure 6 Process Flow of System Solution: ATO Make with Outside Processing
Figure 7 Step 1: ATO Make SO Line Booked with Status of Supply Eligible
When the AutoCreate Final Assembly Orders spawns discrete WIP job 366248, as shown in Figure 9, the
job is created in a Released status. The SO line WF will change the lines status to Production Open.
The WIP job is created with a sales order reservation against the SO line. By clicking the Sales Orders
button on the Discrete Jobs form [Figure 9], the WIP module user can see the form displayed in Figure 10.
This Sales Orders form reveals that order # 71003203 has reserved 30 units against this job.
This sales order reservation is also viewable in the Order Management module via the Actions button on the
SO line. The action Supply To Order Workbench will open an HTML page like the page in Figure 11.
Note: Once the WIP job completes in subsequent Step 6, the SO line reservation is no longer visible
through the methods shown in Figures 10 and 11. The reason is that the SO line reservation is replaced by
a finished goods Inventory reservation.
Using seeded EBS OSP functionality, the resource spawns a purchase requisition that is imported into the
Purchasing module in an Approved status. Figure 13 indicates that Requisition 53201 line 1 was imported
from WIP job 366248.
Figure 15 reveals the link between PO 11294 line 1 and discrete WIP job 366248 as captured on the
Distributions form of the PO line shipment. The PO line distribution has a destination type of Shop Floor
with a quantity of 30. The Distributions form includes an Outside Services button which, when clicked,
displays an Outside Processing form. The Outside Processing form references the WIP job, 366248, and
the OSP resource, OSP_LSR123. The form also shows a resource and assembly quantity of 30.
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When the WIP assembly completion quantities are added to Inventory, an Inventory reservation for the
quantities is created automatically against the ATO Make SO line. The completion process essentially
replaces the SO reservation against the WIP job (created in Step 2) with a SO reservation against Inventory.
Figure 19 shows the Inventory reservation of sales order 71003203 against 30 completed units of
LASER123.
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Figure 20 Step 8: Run the WIP Concurrent Request to Close Discrete Jobs
After the Close Discrete Jobs request was run, discrete WIP job 366248 has a status of Closed in Figure
21. The closing of the WIP job creates resource accounting distributions valued at $100 per unit.
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Issues
Issue 1: Confusion with Seeded OSP Functionality
The outside processing requisition and PO under the standard EBS OSP model uses a fake, or
non-physical, OSP services item as the ordered item. The non-physical OSP item is defined in the item
master but has no standard cost or quantity on-hand (QOH). The OSP PO, for example, might show an
ordered item number of OSP_SERVICES for services to build item LASER123. The OSP PO would not
show item LASER123 as the ordered item under the standard EBS offering.
How would the CM receiving the OSP PO know which FG item to assemble based on an ordered item of
OSP_SERVICES?
Likewise, receipts against an OSP PO under the standard EBS OSP model are recorded against the
non-physical OSP PO item on the PO even though the receiver physically receives the assembled item.
How would a person at the receiving dock know to match the physical receipt of assembled item LASER123
to a PO with ordered item OSP_SERVICES?
Opnexts solution was to deviate from the standard EBS OSP offering and set up the ATO Make FG item
also as the outside processing item. This alternative was suggested by Opnexts consultant for this
implementation from Colibri, Ltd. It eliminated the need to create any non-physical OSP items in the item
master. No Oracle documentation was found that addressed this alternative.
The impact of this solution was twofold:
It allowed the OSP PO to show the assembled item, for instance, LASER123, as the ordered item
on the PO line.
It enabled receipts for the OSP PO to be made against the physically-received item, LASER123.
Figure 22 shows the necessary Purchasing attributes for ATO Make item LASER123. The Outside
Processing flag for this physical item is checked on and the OSP unit type is set to Assembly. The List
Price shown is $100, which is the per-unit charge for assembly services that will appear on OSP POs.
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Under Opnexts solution, the ATO Make item is then linked to the OSP resource in the Outside Processing
region of the Resources form. Resource OSP_LSR123 in Figure 23 was created for this example. A
unique resource must be created for every ATO Make item under Opnexts solution, because each
resource has a specific ATO Make item as its selected Outside Processing item in lieu of a non-physical
OSP item under the standard EBS model. The non-physical OSP item under the standard EBS model
could theoretically be shared across different assemblies via a common resource.
Figure 23 also shows that the Costed flag for resource OSP_LSR123 is checked on and the resource has a
Frozen standard cost of $100 per unit. The Frozen cost of the resource was manually set to the same value
as the List Price of the ATO Make item. The Resource Costs form becomes visible by clicking the Rates
button.
As noted in a previous section, the routing on the WIP job only has one step an outside processing step.
The routing for LASER123 is displayed in Figure 24 with only one step, sequence 10 for department
OPP_CM. What makes this an outside processing step is the resource assigned to the department on the
routing. Figure 24 shows the selected operation resource, OSP_LSR123, which has been defined as a
costed outside processing resource in Figure 23 above.
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The standard cost of resource OPS_LSR123 is $100 [from Figure 23]. The PPV for the OSP PO receipt of
LASER123 was therefore calculated as ($100 - $100) * Quantity Received, or zero PPV, as desired.
Once Opnext implemented this alternative, accountants verified that the OSP PO receipts were recorded as
expected on EBS receiving transaction reports, PPV reports, and the Accrual Reconciliation Report.
A Move processing record for the failed WIP completion became stuck on the
WIP_MOVE_TXN_INTERFACE table with a process status set to 3 for Error.
The OSP PO line misleadingly reflected the receipt in its Quantity Received even though the
physically-received ATO Make item quantities were not added to Inventory.
If the OSP PO line had been fully received, the line was closed for receiving.
Opnext created a Forms Personalization in the Receipts form to perform an error check for insufficient
component quantity in the supply subinventory. The personalization applied only to receipts for outside
processing PO lines (destination type = Shop Floor). If the error condition were met, the personalization
prevented the recording of the OSP PO receipt. An example of the personalization error message appears
in Figure 25. The user would have to re-attempt the receipt transaction after sufficient QOH had been
added to the supply subinventory.
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An example of the seeded workflow notification for the planner is presented in Figure 27. The quantity on
sales order 71003145 line 1.1 has changed from 5 to 30. The notification makes a point to tell the recipient
to . . . review the impact of these changes . . . and take appropriate action.
The user received no notification of the reserved quantities or the failed RTS transaction.
The ATO Make item quantities were not relieved from Inventory via the RTS transaction.
A Move validation record for the failed return got stuck on the WIP_MOVE_TXN_INTERFACE
table with a process status set to 1 for Pending.
To prevent this issue, Opnext created a Forms Personalization in the Receiving Returns form to perform an
error check for unavailable quantity on-hand. The personalization applied only to returns of receipts for
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outside processing PO lines (destination type = Shop Floor). When the error condition occurred, the
personalization prevented the recording of the return to supplier transaction. An example of the
personalization error message appears in Figure 28.
Figure 28 Personalization to Prevent a Return When Insufficient ATO Item Available Quantity
Conclusion
Opnext found ATO Make with Outside Processing to be a cost-effective solution to counter the business
issues which arose from its original Finished Goods Buy turnkey solution. The solution presented in this
white paper can be implemented in an existing Oracle EBS 11i or Release 12 instance most likely without
outside resources such as functional consultants.
ATO Make functionality and Outside Processing functionality each span several EBS modules and can be
confusing for an end-user to comprehend fully. The purpose for this white paper is to help other
organizations with an EBS system understand the combination of ATO Make and Outside Processing.
When combined, both functional processes can facilitate the outside processing of consigned components
as initiated by customer sales orders. While Opnext tried to automate as many steps as possible, the need
arose for Forms Personalizations, workflow notifications, and custom Discoverer queries to allow Opnext
users to survive the post-implementation of this cross-module solution.
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